Packaging insert

ABSTRACT

An insert for a crate end cap is disclosed. The insert includes a substrate having a main body portion and a foldable tab extending from an edge of the main body portion. A plurality of support members is coupled to a surface of the substrate, at least one support member being coupled to the main body portion and at least one other support member being coupled to the foldable tab. The insert is removably received within a cavity of the crate end cap and maintained therein by a frictional engagement between the insert and the walls of the crate end cap forming the cavity thereof. The insert provides cushioning for objects placed in the cavity of the crate end cap.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional patent application Ser. No. 61/227,292 filed Jul. 21, 2009, hereby incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a packaging insert, and more specifically to a crate end cap insert.

BACKGROUND OF THE INVENTION

Packaging inserts are employed to provide cushioning to objects placed in an associated package such as a shipping crate. Shipping crates are often custom designed to be used on multiple occasions for shipping specific objects. For example, a crate assembly, including associated inserts, is typically employed to ship flat glass from a manufacturer to an end user. Upon receipt of the flat glass, the end user removes the flat glass and then returns the crate assembly to the manufacturer. The returned crate assembly can be reused by the manufacturer.

In some applications, the inserts are also designed to be used on multiple occasions. However, the inserts typically have a useful life that is shorter than the useful life of the remainder of the crate assembly. If damaged, the inserts may be replaced and the remainder of the crate assembly can continue to be used.

The inserts are typically installed in the crate assembly by attaching the inserts to an interior surface of the crate assembly employing a plurality of fasteners such as staples or nails, for example. In the event the inserts are damaged, the fasteners can be extracted, the damaged inserts removed, and new inserts attached to the interior of the crate assembly employing new fasteners. The process of extracting the fasteners and attaching new inserts with new fasteners is a time consuming process which increases a cost of shipping the associated objects.

It has been observed that the fasteners employed to attach the inserts to the interior of the crate assembly may become dislodged therefrom during shipment. The dislodged fasters have been known to damage the objects within the crate assembly. In particular, in crate assemblies for shipping plate glass, such dislodged fasteners have been known to scratch, chip, or crack the plate glass.

It would be desirable to produce an insert for a crate assembly to minimize a time required to install the insert in the crate assembly and to minimize damage to objects contained therein.

SUMMARY OF THE INVENTION

Compatible and attuned with the present invention, an insert for a crate assembly to minimize a time required to install the insert in the crate assembly and to minimize damage to objects contained therein, has surprisingly been discovered.

In one embodiment, an insert for a crate end cap comprises a substrate having a main body portion and a foldable tab extending from an edge of the main body portion; a first support member coupled to the main body portion; and a second support member coupled to the foldable tab, the insert removably received within a cavity formed in the crate end cap and maintained therein by a frictional engagement between the inert and a wall forming the cavity of the crate end cap.

In another embodiment, a crate assembly comprises a first end cap having a cavity formed therein; a second end cap having a cavity formed therein, the second end cap spaced from the first end cap; a base having one end disposed in the cavity formed in the first end cap and an opposite end disposed in the cavity formed in the second end cap; an insert disposed in the cavity of each of the end caps, the insert including a substrate having a main body portion and a foldable tab extending from an edge of the main body portion, a first support member coupled to the main body portion, and a second support member coupled to the foldable tab, wherein the insert is maintained within the cavity of the end cap by a frictional engagement between the insert and a wall forming the cavity of the end cap; and at least one tension band to urge the end caps toward one another and secure the base and the object therebetween, wherein the inserts are disposed between the end caps and the object.

In another embodiment, a crate assembly comprises a first end cap having a wall forming a cavity therein; a second end cap having a wall forming a cavity therein, the second end cap spaced from the first end cap; a base having one end disposed in the cavity formed in the first end cap and an opposite end disposed in the cavity formed in the second end cap; a first insert disposed in the cavity formed in the first end cap and a second insert disposed in the cavity formed in the second end cap, each of the inserts including a substrate having a main body portion and a foldable tab extending from an edge of the main body portion, a first support member coupled to the main body portion, and a second support member coupled to the foldable tab, wherein the substrate of the first insert abuts the wall forming the cavity of the first insert and the first support member of the second insert abuts the wall forming the cavity of the second insert; at least one sheet of material having a first end disposed in the cavity formed in the first end cap and a second end disposed in the cavity formed in the second end cap, wherein the first insert is interposed between the first end cap and the first end of the sheet of material and the second insert is interposed between the second end cap and the second end of the sheet of material; and at least one tension band to urge the end caps toward one another and secure the base and the sheet of material therebetween.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the invention, will become readily apparent to those skilled in the art from the following detailed description of an embodiment of the invention when considered in the light of the accompanying drawings and photos, in which:

FIG. 1 is a perspective view of a crate assembly having a first end cap and a second end cap for holding sheets of material therebetween;

FIG. 2 is an exploded perspective view of an insert and the first end cap shown in FIG. 1, the insert configured to be removably received within the first end cap;

FIG. 3 is an exploded perspective view of the insert and the second end cap shown in FIG. 1, the insert configured to be removably received within the second end cap; and

FIG. 4 is a plan view of an insert having a portion thereof cut-away.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description and appended drawings describe and illustrate an exemplary embodiment of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner.

FIGS. 1-3 show a crate assembly 10 for holding a plurality of sheets of material 12 such as plate glass, laminate sheets, and sheets of marble or stone, for example. It should be understood that the crate assembly 10 can be used to hold other types of materials and objects such as posts, beams, and irregularly shaped objects, for example. The crate assembly 10 includes a first end cap 14 and a second end cap 20 spaced from the first end cap 14. It should be understood that the end caps 14, 20 can formed from wood, plastic, composite, and metallic materials, or a combination thereof. The end caps 14, 20 include a cavity 16, 22, respectively, adapted to receive an insert 30 and the ends of the sheets of the material 12. A base 26 is interposed between the end caps 14, 20 to support the sheets of material 12. Opposing ends of the base 26 are received within the cavities 16, 22 of the respective end caps 14, 20. Cross-members 18, 24 are respectively disposed in the cavities 16, 22 adjacent a bottom end thereof. The cross-members 18, 24 support the ends of the base 26 and provide a gap between the base 26 and a supporting surface such as a floor, for example, to facilitate lifting the crate assembly 10 with a fork lift or the like. It should be understood that the base 26 can be formed from one or more cooperating members such as wooden, composite, metallic boards or sheets, or combinations thereof, for example. A plurality of tension bands 28 is typically employed to urge the end caps 14, 20 toward one another and secure the sheets of material 12 and the base 26 therebetween. It should be understood that other means may be employed to secure the sheets of material 12 and the base 26 between the end caps 14, 20 such as fastening strips having opposing ends, wherein the ends of the fastening strips are coupled to the end caps 14, 20.

The insert 30, more clearly shown in FIG. 4, includes a substrate 32 having a main body portion 34 and a foldable tab 36 extending from an edge of the main body portion 34. The main body portion 34 is formed to substantially match the general shape of the cavities 16, 22 of the end caps 14, 20. Favorable results have been obtained employing corrugated cardboard and corrugated plastic sheets having a plurality of flutes 38 for the substrate 32. It should be understood that other materials may be employed for the substrate 32 such as paper board and foam board, for example. In the illustrated embodiment, the foldable tab 36 extends along a portion of the length of the edge of the main body portion 34. It should be understood that the foldable tab 36 can extend along substantially the entire length of the edge of the main body portion 34. A crease 40 may be formed in the substrate 32 between the main body portion 34 and the foldable tab 36 to facilitate pivoting the foldable tab 36 in respect of the main body portion 34. It should be understood that more than one foldable tab can provided and that foldable tabs can be provided at each edge of the main body portion 34.

Two spaced apart elongate first support members 42 are coupled to the main body portion 34 of the substrate 32. The first support members 42 extend from adjacent one edge of the main body portion 34 to an opposite edge thereof. A longitudinal axis of the first support members 42 and the flutes 40 of the corrugated material of the substrate 32 are substantially parallel with each other and oriented perpendicular in respect of the peripheral edges of the sheets of material 12 to maximize a cushioning thereof. It should be understood that a single first support member 42 or more than two first support members 42 may be coupled to the main body portion 34 of the substrate 32. At least one second support member 44 is coupled to the foldable tab 36 of the substrate 32. The second support member 44 is spaced from the fold line 38 a distance substantially equivalent to a thickness of the first support members 42 to facilitate pivoting the foldable tab 36 toward the side of the main body portion 34 having the first support members 42 coupled thereto. Favorable results have been obtained employing fiber board for the support members 42, 44. It should be understood that other materials may be employed for the support members 42, 44 such as corrugated materials, elastomeric materials, plastic materials, and combinations thereof, for example. Additionally, favorable results have been obtained employing an adhesive such as glue or a double sided pressure sensitive tape, for example, to couple the support members 42, 44 to the substrate 32.

As shown in FIGS. 2-3, one insert 30 is removably received within each of the cavities 16, 22 of the respective end caps 14, 20. The insert 30 is maintained within the cavities 16, 22 of the respective end caps 14, 20 by a frictional engagement between the insert 30 and the walls forming the cavities 16, 22 of the end caps 14, 20. The insert 30 is positioned between the end caps 14, 20 and the ends of the sheets of material 12 to provide a cushioning layer between the end caps 14, 20 and the sheets of material 12. The inserts 30 are oriented to place the respective foldable tabs 36 on the same side of the crate assembly 10 when the cavities 16, 22 of the end caps 14, 20 are facing each other. Typically, the insert 30 is oriented to place the foldable tab 36 and the associated second support member 44 along a vertical side of the end caps 14, 20. It should be understood that the insert 30 can be oriented to place the foldable tab 36 and the associated second support member 44 along a horizontal side of the end caps 14, 20.

As shown in FIG. 2 for the first end cap 14, the foldable tab 36 of the insert 30 is folded along the crease 40 toward the side of the main body portion 34 of the substrate 32 having the first support members 42. The insert 30 is removably received within the cavity 16 of the first end cap 14, wherein the substrate 32 abuts the walls forming the cavity 16 of the first end cap 14 and the support members 42, 44 face outwardly from the walls forming the cavity 16 of the first end cap 14. As shown in FIG. 3 for the second end cap 20, the foldable tab 36 of the insert 30 is folded along the crease 40 away from the side of main body portion 34 of the substrate 32 having the first support members 42. The insert 30 is removably received within the cavity 22 of the second end cap 20, wherein the support members 42, 44 abut the walls forming the cavity 22 of the second end cap 20 and the substrate 32 faces outwardly from the walls forming the cavity 22 of the second end cap 20.

In use, an insert 30 is disposed in the cavities 16, 22 of each of the end caps 14, 20. The sheets of material 12 are typically vertically stacked on the base 26. Opposing ends of the base 26 and the sheets of material 12 are received within the cavities 16, 22 of the respective end caps 14, 20 having the inserts 30 disposed between the end caps 14, 20 and the respective ends of the sheets of material 12. The tension bands 28 are employed to urge the end caps 14, 20 toward one another and secure the sheets of material 12 and the base 26 therebetween.

The insert 30 can be quickly installed in and removed from the end caps 14, 20 to minimize a cost of the crate assembly 10 and a cost of replacing a damaged insert. Further, the insert 30 eliminates the use of mechanical fasteners such as nails, brads, and staples, for example, to secure the insert 30 within the cavities 16, 22 of the end caps 14, 20, which minimizes damage to objects within the crate assembly 10 caused by the mechanical fasteners.

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions. 

1. An insert for a crate end cap comprising; a substrate having a main body portion and a foldable tab extending from an edge of the main body portion; a first support member coupled to the main body portion; and a second support member coupled to the foldable tab, the insert removably received within a cavity formed in the crate end cap and maintained therein by a frictional engagement between the insert and a wall forming the cavity of the crate end cap.
 2. The insert according to claim 1, wherein the substrate is a corrugated material having a plurality of flutes formed therein.
 3. The insert according to claim 2, wherein the flutes of the corrugated material are substantially parallel to a longitudinal axis of the first support member.
 4. The insert according to claim 2, wherein the flutes of the corrugated material are substantially perpendicular to a longitudinal axis of the second support member.
 5. The insert according to claim 1, wherein at least one of the first support member and the second support member is formed from a paperboard material.
 6. The insert according to claim 1, further comprising an adhesive disposed between the substrate and the first support member and between the substrate and the second support member.
 7. The insert according to claim 1, further comprising a plurality of the first support members.
 8. A crate assembly comprising: a first end cap having a cavity formed therein; a second end cap having a cavity formed therein, the second end cap spaced from the first end cap; a base having one end disposed in the cavity formed in the first end cap and an opposite end disposed in the cavity formed in the second end cap; an insert disposed in the cavity of each of the end caps, the insert including a substrate having a main body portion and a foldable tab extending from an edge of the main body portion, a first support member coupled to the main body portion, and a second support member coupled to the foldable tab, wherein the insert is maintained within the cavity of the end cap by a frictional engagement between the insert and a wall forming the cavity of the end cap; and at least one tension band to urge the end caps toward one another and secure the base and the object therebetween, wherein the inserts are disposed between the end caps and the object.
 9. The crate assembly according to claim 8, further comprising an object having a first end disposed in the cavity formed in the first end cap and a second end disposed in the cavity formed in the second end cap, wherein the first insert is interposed between the first end cap and the first end of the object and the second insert is interposed between the second end cap and the second end of the object.
 10. The crate assembly according to claim 8, wherein the substrate of the insert disposed in the cavity of the first end cap abuts the wall forming the cavity therein and the first support member of the insert disposed in the cavity of the second end cap abuts the wall forming the cavity therein.
 11. The crate assembly according to claim 8, wherein the substrate of the insert is a corrugated material having a plurality of flutes formed therein and at least one of the first support member and the second support member is formed from a paperboard material.
 12. The crate assembly according to claim 11, wherein the flutes of the corrugated material are substantially parallel to a longitudinal axis of the first support member and substantially perpendicular to a longitudinal axis of the second support member.
 13. The crate assembly according to claim 8, further comprising an adhesive disposed between the substrate and the first support member and between the substrate and the second support member.
 14. A crate assembly comprising: a first end cap having a wall forming a cavity therein; a second end cap having a wall forming a cavity therein, the second end cap spaced from the first end cap; a base having one end disposed in the cavity formed in the first end cap and an opposite end disposed in the cavity formed in the second end cap; a first insert disposed in the cavity formed in the first end cap and a second insert disposed in the cavity formed in the second end cap, each of the inserts including a substrate having a main body portion and a foldable tab extending from an edge of the main body portion, a first support member coupled to the main body portion, and a second support member coupled to the foldable tab, wherein the substrate of the first insert abuts the wall forming the cavity of the first insert and the first support member of the second insert abuts the wall forming the cavity of the second insert; at least one sheet of material having a first end disposed in the cavity formed in the first end cap and a second end disposed in the cavity formed in the second end cap, wherein the first insert is interposed between the first end cap and the first end of the sheet of material and the second insert is interposed between the second end cap and the second end of the sheet of material; and at least one tension band to urge the end caps toward one another and secure the base and the sheet of material therebetween.
 15. The crate assembly according to claim 14, wherein the substrate of the insert is a corrugated material having a plurality of flutes formed therein
 16. The crate assembly according to claim 15, wherein the flutes of the corrugated material are substantially parallel to a longitudinal axis of the first support member and perpendicular to a peripheral edge of the sheet of material.
 17. The crate assembly according to claim 15, wherein the flutes of the corrugated material are substantially perpendicular to a longitudinal axis of the second support member.
 18. The crate assembly according to claim 14, wherein at least one of the first support member and the second support member is formed from a paperboard material.
 19. The insert according to claim 14, further comprising a plurality of the first support members.
 20. The crate assembly according to claim 9, further comprising an adhesive disposed between the substrate and the first support member and between the substrate and the second support member. 